Owners Manual

CAUTION
Before using this product, read this manual and follow all Safety Rules and Operating Instructions.

Questions? Help is just a moment away!

Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT Web: www.generac-portables.com or www.briggsandstratton.com Model No. 9777-4 (4,000 Watt AC Generator) Manual No. 193524GS Revision 2 (08/03/2005)

4000XL Extended Life Generator

TABLE OF CONTENTS
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SAFETY RULES
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION,WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. CAUTION, when used without the alert symbol, indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

EQUIPMENT DESCRIPTION
Read this manual carefully and become familiar with your generator. Know its applications, its limitations and any hazards involved. The generator is an enginedriven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads.The generators revolving field is driven at about 3,600 rpm by a singlecylinder engine.

WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Hazard Symbols and Meanings

CAUTION! DO NOT exceed the generators

wattage/amperage capacity. See Dont Overload Generator. Every effort has been made to ensure that information in this manual is accurate and current. However, we reserve the right to change, alter or otherwise improve the product and this document at any time without prior notice. The Emissions Control System for this generator is warranted for standards set by the Environmental Protection Agency. For warranty information refer to the engine owners manual. Kickback Explosion Fire Toxic Fumes Electrocution Electrical Shock

Explosive Pressure

Chemical Burn

Hot Surface

Copyright 2005 Briggs & Stratton Power Products Group, LLC. All rights reserved. No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs & Stratton Power Products Group, LLC.

4000XL Extended Life Generator

DANGER
Storage batteries give off explosive hydrogen gas during recharging. Hydrogen gas stays around battery for a long time after battery has been charged. Slightest spark will ignite hydrogen and cause explosion. You can be blinded or severely injured. Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery fluid will cause severe chemical burns.
DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery. Wear protective goggles, rubber apron, and rubber gloves.

WARNING
Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.
WHEN ADDING OR DRAINING FUEL Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank. Fill or drain fuel tank outdoors. DO NOT overfill tank. Allow space for fuel expansion. Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources. DO NOT light a cigarette or smoke. WHEN STARTING EQUIPMENT Ensure spark plug, muffler, fuel cap and air cleaner are in place. DO NOT crank engine with spark plug removed. If fuel spills, wait until it evaporates before starting engine. WHEN OPERATING EQUIPMENT Do not tip engine or equipment at angle which causes fuel to spill. This generator is not for use in mobile equipment or marine applications. WHEN TRANSPORTING OR REPAIRING EQUIPMENT Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF. Disconnect spark plug wire. WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK Store away from furnaces, stoves, water heaters, clothes dryers or other appliances that have pilot light or other ignition source because they can ignite fuel vapors.

WARNING
Running generator gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting or death.
Operate generator ONLY outdoors. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings. DO NOT operate generator inside any building or enclosure (even if doors and windows are open), including the generator compartment of a recreational vehicle (RV).

WARNING
Generator produces powerful voltage. Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy.
When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility. Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work. DO NOT touch bare wires or receptacles. DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged. DO NOT operate generator in the rain or wet weather. DO NOT handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet. DO NOT allow unqualified persons or children to operate or service generator.

WARNING
This generator does not meet U. S. Coast Guard Regulation 33CFR-183 and should not be used on marine applications. Failure to use the appropriate U. S. Coast Guard approved generator could result in death or serious injury and/or property damage.

4000XL Extended Life Generator

WARNING
Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go. Broken bones, fractures, bruises or sprains could result.
When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback. NEVER start or stop engine with electrical devices plugged in and turned on.

CAUTION
Excessively high operating speeds increase risk of injury and damage to generator. Excessively low speeds impose a heavy load.
DO NOT tamper with governed speed. Generator supplies correct rated frequency and voltage when running at governed speed. DO NOT modify generator in any way.

CAUTION
Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.
See Dont Overload Generator. Start generator and let engine stabilize before connecting electrical loads. Connect electrical loads in OFF position, then turn ON for operation. Turn electrical loads OFF and disconnect from generator before stopping generator.

WARNING
Unintentional sparking can result in fire or electric shock.
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug. WHEN TESTING FOR ENGINE SPARK Use approved spark plug tester. DO NOT check for spark with spark plug removed.

CAUTION
Improper treatment of generator can damage it and shorten its life.
Use generator only for intended uses. If you have questions about intended use, ask dealer or call 1-800-270-1408. Operate generator only on level surfaces. DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors. DO NOT insert any objects through cooling slots. If connected devices overheat, turn them off and disconnect them from generator. Shut off generator if: -electrical output is lost; -equipment sparks, smokes, or emits flames; -unit vibrates excessively.

WARNING
Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150F (65C). Severe burns can occur on contact. Combustible debris, such as leaves, grass, brush, ect. can catch fire.
DO NOT touch hot surfaces. Allow equipment to cool before touching. The generator must be at least 5 feet from structures having combustible walls and/or other combustible materials. Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing. Reflective exhaust heat may damage fuel tank causing fire. Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1C or later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

4000XL Extended Life Generator

KNOW YOUR GENERATOR

Read this owners manual and safety rules before operating your generator. Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference. Fuel Tank Oil Fill Cap Circuit Breakers (AC) Recoil Starter

Run/Stop Switch 120/240 Volt AC, 20 Amp Receptacle Choke Lever

120 Volt AC, 30 Amp Receptacle 12 Volt DC, 10 Amp Receptacle 120 Volt AC, 15 Amp Duplex Receptacle Idle Control Switch 12 Volt DC,10 Amp Receptacle Recharge a discharged 12 Volt automotive type battery through this receptacle. 120 Volt AC, 15 Amp Duplex Receptacle May be used to supply electrical power for the operation of 120 Volt AC, 15 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads. 120 Volt AC, 30 Amp Receptacle May be used to supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads. 120/240 Volt AC, 20 Amp Receptacle May be used to supply electrical power for the operation of 120 and/or 240 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads. Air Cleaner Uses a dry type filter element and foam precleaner to limit the amount of dirt and dust sucked into the engine.

Air Cleaner

Spark Arrester Muffler Grounding Fastener Choke Lever Used when starting a cold engine. Circuit Breakers (AC) Each receptacle is provided with a "push to reset" circuit breaker to protect the generator against electrical overload. Fuel Tank Capacity of 4.5 U.S. gallons. Grounding Fastener Consult your local agency having jurisdiction for grounding requirements in your area. Idle Control Switch With this switch set to ON, printed circuit board in control panel automatically reduces engine speed when no load is connected and increases engine to proper speed when load is applied. However, be sure switch is OFF when starting engine. Oil Fill Cap Add oil to engine here. Recoil starter Used to start the engine manually. Run/Stop Switch Set this switch to "Run" before using recoil starter. Set switch to "Stop" to switch OFF engine. Spark Arrester Muffler Exhaust muffler lowers engine noise and is equipped with a spark arrester screen.

4000XL Extended Life Generator

ASSEMBLY
Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel. If you have any problems with the assembly of your generator, please call the generator helpline at 1-800-270-1408.

Locking 20A plug Locking 30A plug Oil bottle Owners manual Engine manual If any of the above parts are missing or damaged, call the helpline at 18002701408.

Remove Generator From Carton

1. 2. 3. 4. 5. Set carton on a rigid flat surface with This Side Up arrows pointing upward. Carefully open top flaps of shipping carton. Review Cold Weather Operation on page 10. Cut down corners at one end of carton from top to bottom and lay that side of carton down flat. Remove all packing material, carton fillers, etc. Remove generator from shipping carton.

Install Wheel Kit

NOTE: Wheel kit is not intended for over-the-road use. You will need the following tools to install these components: 2 - 1/2" or 13mm wrenches Pliers Refer to Figure 1 and install the wheel kit as follows: 1. Tip generator so that engine end is up. 2. 3. 4. 5. 6. 7. Slide axle through both mounting brackets. Place a wheel on each side with air valve facing out. Place a washer on axle and then place an e-ring in axle groove. Install e-ring with pliers, squeezing from top of e-ring to bottom of axle. Repeat step 4 and 5 to secure second wheel. Tip generator so that engine side is down.

Carton Contents
Items in the carton include: Generator Wheel Kit Storage cover Battery charge cables Spare spark pug, air filter and oil filter Spark plug wrench
Figure 1 Install Wheel Kit

Cap Screw

Hex nut Handle Flat Washer Axle Mounting Leg Use Existing Fasteners Wheel

E-Ring

4000XL Extended Life Generator

8.

Remove existing hardware from vibration mounts with 13mm wrench. Use same hardware to attach mounting leg. Center handle bracket on generator frame at control panel end of cradle.

Add Fuel
NOTE: This gasoline engine is certified to operate on gasoline. Exhaust Emission Control System: EM (Engine Modifications).

9.

10. Attach handle bracket with two cap screws and two hex nuts. Use two 13 mm wrenches to tighten hardware. 11. Return generator to normal operating position (resting on wheels and support leg). 12. Check that all fasteners are tight and tires are inflated between 15-40 PSI.

WARNING
Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.
WHEN ADDING FUEL Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank. Fill fuel tank outdoors. DO NOT overfill tank. Allow space for fuel expansion. Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources. DO NOT light a cigarette or smoke.

BEFORE STARTING THE ENGINE

Add Engine Oil
Place generator on a level surface.

1.

CAUTION
Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure.
Refer to engine manual for oil fill information. Damage to equipment resulting from failure to follow this instruction will void warranty.

Use clean, fresh, regular UNLEADED fuel with a minimum of 85 octane with equipment. DO NOT use fuel which contains Methanol. DO NOT mix oil with fuel. Clean area around fuel fill cap, remove cap. Slowly add regular unleaded fuel to fuel tank. Be careful not to fill above the baffle.This allows adequate space for fuel expansion (Figure 2).
Figure 2 Typical Fuel Expansion Space
TANK

2. 3.

Refer to engine owners manual and follow oil recommendations and instructions. NOTE: Check oil often during engine breakin. Refer to engine owners manual for recommendations. NOTE: The generator assembly rotates on a prelubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing. 4.

Baffle
FUEL

Install fuel cap and wipe up any spilled fuel.

4000XL Extended Life Generator

USING THE GENERATOR

System Ground
The generator has a system ground that connects the generator frame components to the ground terminals on the AC output receptacles.The system ground is connected to the AC neutral wire (the neutral is bonded to the generator frame). Special Requirements There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction. In some areas, generators are required to be registered with local utility companies. If the generator is used at a construction site, there may be additional regulations which must be observed.

Generator Location
Generator Clearance

WARNING
Running generator gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide will cause nausea, fainting or death.
Operate generator ONLY outdoors. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings. DO NOT operate generator inside any building or enclosure (even if doors or windows are open), including the generator compartment of a recreational vehicle (RV).

The generator must be at least 5 ft. (152 cm) from structures having combustible walls and/or other combustible materials. Leave at least 3 ft. (92 cm) all around generator including overhead, for adequate cooling, maintenance and servicing. Place generator in a well ventilated area, which will allow for removal of deadly exhaust gas. DO NOT place generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from any windows, doors, ventilation intakes or other openings that can allow exhaust gas to collect in a confined area (Figure 3). Prevailing winds and air currents should be taken into consideration when positioning generator.
Figure 3 Generator Clearance

Connecting to a Buildings Electrical System

Connections for standby power to a buildings electrical system must be made by a qualified electrician.The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes.

WARNING
Generator produces powerful voltage. Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy.
When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility. Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work. DO NOT touch bare wires or receptacles. DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged. DO NOT operate generator in the rain. DO NOT handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet. DO NOT allow unqualified persons or children to operate or service generator.

Typical Generator Shown

Exhaust Port

4000XL Extended Life Generator

OPERATING THE GENERATOR

Starting the Engine
Disconnect all electrical loads from the generator. Follow these start instruction steps in numerical order: 1. Make sure unit is on a level surface. IMPORTANT: Failure to start and operate unit on a level surface will cause the unit not to start or shut down during operation. 2. Turn fuel valve to On position (Figure 4).
Figure 4 Fuel Shut-off Valve

WARNING
Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150F (65C). Severe burns can occur on contact. Combustible debris, such as leaves, grass, brush, ect. can catch fire.
DO NOT touch hot surfaces. Allow equipment to cool before touching. The generator must be at least 5 feet from structures having combustible walls and/or other combustible materials. Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing. Reflective exhaust heat may damage fuel tank causing fire. Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1C or later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

3.

Make sure Idle Control switch is in Off position (Figure 5).

Figure 5 Idle Control Switch

Connecting Electrical Loads

Let engine stabilize and warm up for a few minutes after starting. Plug in and turn on the desired 120 and/or 240 Volt AC, single phase, 60 Hz electrical loads. DO NOT connect 240 Volt loads to the 120 Volt receptacles. DO NOT connect 3phase loads to the generator. DO NOT connect 50 Hz loads to the generator. DO NOT OVERLOAD THE GENERATOR. See Dont Overload Generator.

3.

Start engine according to instructions given in engine owners manual.

WARNING
Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go. Broken bones, fractures, bruises or sprains could result.
When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback. NEVER start or stop engine with electrical devices plugged in and turned on.

CAUTION
Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.
See Dont Overload Generator. Start generator and let engine stabilize before connecting electrical loads. Connect electrical loads in OFF position, then turn ON for operation. Turn electrical loads OFF and disconnect from generator before stopping generator.

NOTE: If engine still fails to start after 3 pulls, check for proper oil level in crankcase.This unit is equipped with a Low Oil Shutdown System. See engine manual.

4000XL Extended Life Generator

Stopping the Engine

1. Turn OFF and unplug ALL electrical loads from generator panel receptacles. NEVER start or stop engine with electrical devices plugged in and turned ON. Move idle control switch to Off position. Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator. Turn engine off according to instructions given in the engine owners manual. Move fuel valve to Off position.

2. 3. 4. 5.

2. 3. 4. 5.

If battery is equipped with vent caps, make sure they are installed and are tight. If necessary, clean battery terminals. Connect battery charge cable connector plug to panel receptacle identified by the words 12-VOLTS D.C.. Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 6).
Figure 6 Battery Connections

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy. When this switch is turned ON, the engine will only run at its normal high governed engine speed when electrical loads are connected.When an electrical load is removed, the engine will run at a reduced speed. With the switch off, the engine will run at the normal high engine speed. Always have the switch off when starting and stopping the engine.

6. 7. 8.

Connect battery charge cable clamp with black handle to the negative () battery terminal (Figure 6). Start engine. Let engine run while battery recharges. When battery has charged, shut down engine

Charging a Battery
Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery. DO NOT use the unit to charge any 6 Volt batteries. DO NOT use the unit to crank an engine having a discharged battery.

DANGER
Storage batteries give off explosive hydrogen gas during recharging. Hydrogen gas stays near battery for a long time after battery has been charged. Slightest spark will ignite hydrogen and cause explosion. You can be blinded or severely injured. Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery fluid will cause severe chemical burns.
DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery. Wear protective goggles, rubber apron, and rubber gloves.

NOTE: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturers instructions carefully. Generally, a battery is considered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260 or higher.

COLD WEATHER OPERATION

Under certain weather conditions (temperatures below 40F [4C] combined with high humidity), your generator may experience icing of the carburetor and/or the crankcase breather system.To reduce this problem, you need to perform the following: 1. Make sure generator has clean, fresh fuel. 2. Open fuel valve (turn valve to open position). 3. 4. 5. 6. Use SAE 5W-30 oil (synthetic preferred, see engine manual). Check oil level daily or after every eight (8) hours of operation. Maintain generator following Maintenance Schedule in engine manual. Shelter unit from elements.

To recharge 12 Volt batteries, proceed as follows: 1. Check fluid level in all battery cells. If necessary, add ONLY distilled water to cover separators in battery cells. DO NOT use tap water.

10

4000XL Extended Life Generator

In an emergency, use the original shipping carton as a temporary shelter: 7. 8. Cut off all carton flaps. Cut out one long side of carton to expose muffler side of unit as shown in Figure 7.
Figure 7 Permanent Cold Weather Shelter

For a more permanent shelter, build a structure that will enclose three sides and the top of the generator. 7. Make sure entire muffler-side of generator is exposed, as shown in Figure 7.

Wind

IMPORTANT: The generator must be at least 5 ft. (152 cm) from structures having combustible walls and/or other combustible materials. Leave at least 3 ft. (92 cm) all around generator including overhead, for adequate cooling, maintenance and servicing. 8. 9. Face exposed end away from wind and elements. Structure should hold enough heat created by the generator to prevent icing problem.

10. Start and run engine outdoors. 11. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings. IMPORTANT: The generator must be at least 5 ft. (152 cm) from structures having combustible walls and/or other combustible materials. Leave at least 3 ft. (92 cm) all around generator including overhead, for adequate cooling, maintenance and servicing.

DANGER
Running generator gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide will cause nausea, fainting or death.
Operate generator ONLY outdoors. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings. DO NOT operate generator inside any building or enclosure (even if doors or windows are open), including the generator compartment of a recreational vehicle (RV).

WARNING
Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150F (65C). Severe burns can occur on contact. Combustible debris, such as leaves, grass, brush, ect. can catch fire.
DO NOT touch hot surfaces. Allow equipment to cool before touching. The generator must be at least 5 feet from structures having combustible walls and/or other combustible materials. Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing. Reflective exhaust heat may damage fuel tank causing fire. Remove shelter when temperatures are above 40F [4C].

12. DO NOT enclose generator any more than shown in Figure 7. 13. Remove shelter when temperatures are above 40F [4C]. 14. Turn engine OFF and let cool two (2) minutes before refueling.

9.

Cut appropriate slots to access receptacles of unit.

10. Start unit, then place carton over it. NOTE: Remove shelter when temperatures are above 40F [4C].

11

4000XL Extended Life Generator

RECEPTACLES
CAUTION
Receptacles may be marked with rating value greater than generator output capacity.
NEVER attempt to power a device requiring more amperage than generator or receptacle can supply. DO NOT overload the generator. See Dont Overload Generator.

120/240 Volt AC, 20 Amp Locking Receptacle

Use a NEMA L14-20 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts at 20 Amps (or greater) (Figure 9).You can use the same 4-wire cord if you plan to run a 120 Volt load.
Figure 9 120/240 Volt AC, 20 Amp Receptacle

4-Wire Cord Set

120 Volt AC, 15 Amp Receptacles

Each of these outlets is protected against overload by 15 Amp push-to-reset type circuit breakers (Figure 8).
Figure 8 120 Volt AC, 15 Amp Duplex Receptacle

240V 120V 120V W (Neutral)

Y (Hot)

X (Hot) Ground (Green)

NEMA L14-20

Use each outlet to operate 120 Volt, 60 Hz, single phase loads requiring 1,800 (1.8 kW) watts at 15 Amps of current.

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 2,000 watts of power at 16.7 Amps for 120 Volts; 4,000 watts of power (4.0 kW) at 16.7 Amps for 240 Volts.The outlet is protected by a 20 Amp push-to-reset circuit breaker.

12

4000XL Extended Life Generator

120 Volt AC, 30 Amp Locking Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set rated for 125 Volts AC at 30 Amps to the plug (Figure 10).
Figure 10 120 Volt AC, 30 Amp, Locking Receptacle

12 Volt DC, 10 Amp Receptacle

This receptacle (Figure 11) allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided.
Figure 11 12 Volt DC, 10 Amp Receptacle

3-Wire Cord Set

NEMA L5-30
Neutral 120V Hot This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery. See Charging a Battery on page 10 before attempting to recharge a battery.This outlet is protected by a 10 Amp self resetting circuit breaker. Ground (Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3,600 watts (3.6 kW) of power at 30 Amps.The outlet is protected by a 30 Amp push-to-reset circuit breaker.

13

4000XL Extended Life Generator

DON'T OVERLOAD GENERATOR

Capacity
You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you will power at the same time. Follow these simple steps: 1. Select the items you will power at the same time. 2. Total the rated (running) watts of these items.This is the amount of power your generator must produce to keep your items running. See Figure 12. 3. Estimate how many surge (starting) watts you will need. Surge wattage is the short burst of power needed to start electric motor-driven tools or appliances such as a circular saw or refrigerator. Because not all motors start at the same time, total surge watts can be estimated by adding only the item(s) with the highest additional surge watts to the total rated watts from step 2. Example:
Tool or Appliance Window Air Conditioner Refrigerator Deep Freezer Television Light (75 Watts) Rated (Running) Watts 1200 800 500 500 75 3075 Total Running Watts Additional Surge (Starting) Watts 1800 1600 500 1800 Highest Surge Watts

4. Plug in and turn on the next load. 5. Again, permit the generator to stabilize. 6. Repeat steps 4 and 5 for each additional load. NEVER add more loads than the generator capacity.Take special care to consider surge loads in generator capacity, as described above.
Figure 12 - Wattage Reference Chart Tool or Appliance Essentials Light Bulb - 75 watt Deep Freezer Sump Pump Refrigerator/Freezer - 18 Cu. Ft. Water Well Pump - 1/3 HP Heating/Cooling Window AC - 10,000 BTU Window Fan Furnace Fan Blower - 1/2 HP Kitchen Microwave Oven - 1000 Watt Coffee Maker Electric Stove - Single Element Hot Plate Family Room DVD/CD Player VCR Stereo Receiver Color Television - 27 Personal Computer w/17 monitor Other Security System AM/FM Clock Radio Garage Door Opener - 1/2 HP Electric Water Heater - 40 Gallon DIY/Job Site Quartz Halogen Work Light Airless Sprayer - 1/3 HP Reciprocating Saw Electric Drill - 1/2 HP Circular Saw - 7 1/4 Miter Saw - 10 Planer/Jointer - 6 Table Saw/Radial Arm Saw - 10 Air Compressor - 1-1/2 HP Rated* (Running) Watts 75 500 800 800 1000 1200 300 800 1000 1500 1500 2500 100 100 450 500 800 180 300 480 4000 1000 600 960 1000 1500 1800 1800 2000 2500 Additional Surge (Starting) Watts 500 1200 1600 2000 1800 600 1300 520 1200 960 1000 1500 1800 1800 2000 2500

Total Rated (Running) Watts = 3075 Highest Additional Surge Watts = 1800 Total Generator Output Required = 4875

Power Management
To prolong the life of your generator and attached devices, it is important to take care when adding electrical loads to your generator.There should be nothing connected to the generator outlets before starting it's engine.The correct and safe way to manage generator power is to sequentially add loads as follows: 1. With nothing connected to the generator, start the engine as described in this manual. 2. Plug in and turn on the first load, preferably the largest load you have. 3. Permit the generator output to stabilize (engine runs smoothly and attached device operates properly.

*Wattages listed are approximate only. Check tool or appliance for actual wattage.

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4000XL Extended Life Generator

SPECIFICATIONS
Starting Wattage . . . . . . . . . . . . . . . . . . . . . . .6,600 watts Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,000 watts AC Load Current: At 120 Volts . . . . . . . . . . . . . . . . . . . . . . . . .33.3 Amps At 240 Volts . . . . . . . . . . . . . . . . . . . . . . . . .16.7 Amps Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1phase Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . .60 Hertz Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . 4 U.S. gallons Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 134 lbs.

NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. In addition, if water enters generator through cooling air slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation.Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

WARNING
Unintentional sparking can result in fire or electric shock.
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug. WHEN TESTING FOR ENGINE SPARK Use approved spark plug tester. DO NOT check for spark with spark plug removed.

GENERAL MAINTENANCE RECOMMENDATIONS

The Owner/Operator is responsible for making sure that all periodic maintenance tasks are completed on a timely basis; that all discrepancies are corrected; and that the unit is kept clean and properly stored. NEVER operate a damaged or defective generator. NOTE: Should you have questions about replacing components on your Generac Portable Products generator, please call 1-800-270-1408 for assistance.

Fuel Valve Maintenance

The fuel valve is equipped with a fuel sediment cup, screen, retaining ring and o-ring that need to be cleaned every 6 months or 100 hours (whichever occurs first). 1. 2. Move fuel valve to Off position. Remove sediment cup from fuel valve. Remove o-ring, retaining ring and screen from fuel valve (Figure 13).
Figure 13 Fuel Valve Maintenance

Engine Maintenance
See engine owners manual for instructions.

CAUTION
Avoid prolonged or repeated skin contact with used motor oil.
Used motor oil has been shown to cause skin cancer in certain laboratory animals. Thoroughly wash exposed areas with soap and water.

KEEP OUT OF REACH OF CHILDREN. DON'T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

Screen Retaining Ring O-ring Sediment Cup 3. Wash sediment cup, o-ring, retaining ring, and screen in a nonflammable solvent. Dry them thoroughly.

Generator Maintenance
Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves or any other foreign material.

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4000XL Extended Life Generator

4. 5.

Place screen, retaining ring, and o-ring into fuel valve. Install sediment cup and tighten securely. Move fuel valve to On position, and check for leaks. Replace o-ring if there is any leakage.

Generator Storage
Clean the generator as outlined in Generator Cleaning. Check that cooling air slots and openings on generator are open and unobstructed.

Generator Cleaning
Use a damp cloth to wipe exterior surfaces clean.

WARNING
Storage covers can be flammable.
DO NOT place a storage cover over a hot generator. Let equipment cool for a sufficient time before placing the cover on the equipment.

CAUTION
Improper treatment of generator can damage it and shorten its life.
DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors. DO NOT insert any objects through cooling slots.

Engine Storage
See engine owners manual for instructions.

Use a soft bristle brush to loosen caked on dirt or oil. Use a vacuum cleaner to pick up loose dirt and debris. Use low pressure air (not to exceed 25 psi) to blow away dirt. Inspect cooling air slots and opening on generator.These openings must be kept clean and unobstructed.

Other Storage Tips

To prevent gum from forming in fuel system or on essential carburetor parts, add fuel stabilizer into fuel tank and fill with fresh gasoline. Run the unit for several minutes to circulate the additive through the carburetor. The unit and fuel can then be stored for up to 24 months. Fuel stabilizer can be purchased locally. DO NOT store gasoline from one season to another unless it has been treated as described above. Replace fuel container if it starts to rust. Rust and/or dirt in fuel can cause problems if it's used with this unit. Store in clean and dry area.

STORAGE
The generator should be started at least once every seven days and allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following guidelines to prepare it for storage.

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4000XL Extended Life Generator

TROUBLESHOOTING
Problem Cause
1. 2. No AC output is available, but generator is running. 3. 4. Generator runs good at no-load but "bogs" down" when loads are connected. Generator will not start; or starts and runs rough. Generator shuts down during operation. Generator lacks power. 1. 2. 3. Fault in generator.

Correction
Reset circuit breaker. Contact Authorized service facility. Check and repair. Connect another device that is in good condition. Disconnect shorted electrical load. See "Don't Overload Generator". Contact Authorized service facility. 2.

One of the circuit breakers is open. 1. Poor connection or defective cord 3. set. Connected device is bad. Short circuit in a connected load. Generator is overloaded. Shorted generator circuit. 4. 1. 2. 3.

Low oil level. 1. 2. Out of gasoline. Low oil level.

Fill crankcase to proper level or place generator on level surface. 1. 2. Fill fuel tank. Fill crankcase to proper level or place generator on level surface.

Load is too high.

See "Don't Overload Generator".

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4000XL Extended Life Generator

NOTES

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4000XL Extended Life Generator

NOTES

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GENERAC PORTABLE PRODUCTS OWNER EQUIPMENT WARRANTY POLICY Effective November 1, 2004 LIMITED WARRANTY "Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products. Briggs & Stratton Power Products will repair or replace, free of charge, any part, or parts of the equipment** that are defective in material or workmanship or both. Transportation charges on parts submitted for repair or replacement under this warranty must be borne by purchaser.This warranty is effective for the time periods and subject to the conditions provided for in this policy. For warranty service, find your nearest Authorized service dealer by calling 1-800-270-1408.Warranty service may only be performed by a Briggs & Stratton Power Products Authorized service dealer. THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,ARE LIMITED TO THE TIME PERIOD SPECIFIED, OR TO THE EXTENT PERMITTED BY LAW.ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. Some countries or states do not allow limitations on how long an implied warranty lasts, and some countries or states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you.This warranty gives you specific legal rights and you may also have other rights that vary from country to country or state to state. WARRANTY PERIOD*
PRODUCTS** CONSUMER USE COMMERCIAL USE

Pressure Washer Portable Generator

1 year 2 years (2nd year parts only)

90 days 1 year

* The warranty period begins on the date of purchase by the first retail consumer or commercial end user, and continues for the period of time stated in the table above. "Consumer use" means personal residential household use by a retail consumer. "Commercial use" means all other uses, including use for commercial, income producing or rental purposes. Once equipment has been used commercially, it shall thereafter be considered to be in commercial use for purposes of this warranty. ** The engine and starting batteries are warranted solely by the manufacturers of those products. WARRANTY REGISTRATION IS NOT NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON POWER PRODUCTS EQUIPMENT .SAVEYOUR PROOF OF PURCHASE RECEIPT YOU DO NOT PROVIDE PROOF OF THE .IF INITIAL PURCHASE DATE AT THE TIME WARRANTY SERVICE IS REQUESTED,THE MANUFACTURING DATE OF THE EQUIPMENT WILL BE USED TO DETERMINE THE WARRANTY PERIOD. About your equipment warranty: We welcome warranty repair and apologize to you for being inconvenienced.Any Authorized service dealer may perform warranty repairs. Most warranty repairs are handled routinely, but sometimes requests for warranty service may not be appropriate. For example, warranty service would not apply if equipment damage occurred because of misuse, lack of routine maintenance, shipping, handling, warehousing or improper installation. Similarly, the warranty is void if the manufacturing date or the serial number on the equipment has been removed or the equipment has been altered or modified. During the warranty period, the Authorized service dealer, at its option, will repair or replace any part that, upon examination, is found to be defective under normal use and service.This warranty will not cover following repairs and equipment: Normal Wear: Outdoor power equipment, like all mechanical devices, needs periodic parts, service and replacement to perform well.This warranty does not cover repair when normal use has exhausted the life of a part or the equipment. Installation and Maintenance: This warranty does not apply to equipment or parts that have been subjected to improper or unauthorized installation or alteration and modification, misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair or storage so as, in our judgment, to adversely affect its performance and reliability.This warranty also does not cover normal maintenance such as adjustments, fuel system cleaning and obstruction (due to chemical, dirt, carbon or lime, etc.). Other Exclusions: Also excluded from this warranty are wear items such as quick couplers, oil gauges, belts, o-rings, filters, pump packing, etc., pumps which have been run without water supplied or damage or malfunctions resulting from accidents, abuse, modifications, alterations, or improper servicing or freezing or chemical deterioration. Accessory parts such as guns, hoses, wands and nozzles are excluded from the product warranty.This warranty excludes failures due to acts of God and other force majeure events beyond the manufacturers control. Also excluded is used, reconditioned, and demonstration equipment; equipment used for prime power in place of utility power and equipment used in life support applications. BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC JEFFERSON,WISCONSIN, U.S.A.